composite / Panelised / Insulated Panel
Precast panel with integrated insulation core (200mm, 250mm, 300mm, 350mm total sandwich panel)
Precast concrete sandwich panels with a rigid insulation core and composite connectors, delivering structural capacity and continuous insulation in a single prefabricated assembly.
Atlas code
COM-PNL-INS-009
At-a-glance signals
Precast concrete sandwich panels with a rigid insulation core and composite connectors, delivering structural capacity and continuous insulation in a single prefabricated assembly.
Overview
Executive summary
Precast insulated sandwich panels combine two reinforced concrete wythes with a rigid insulation core (EPS or XPS) and composite connectors that reduce thermal bridging. Typical panels use a 3-4 in outer wythe, 3-4 in insulation, and a 3-6 in structural inner wythe, providing both structural capacity and continuous insulation.
Best when…
- Excellent thermal performance with continuous insulation (R2.4-R4.5)
- High fire resistance rating (FRL up to 180/180/180)
- Superior acoustic performance (Rw 50-65)
- Rapid construction with minimal site work
- Factory quality control and precision
- Integrated services and architectural features
- Long service life with minimal maintenance
- Composite action provides enhanced structural capacity
- Suitable for all Australian climate zones
- Complies with NCC energy efficiency requirements
Top advantages
- 01 Excellent thermal performance with continuous insulation (R2.4-R4.5)
- 02 High fire resistance rating (FRL up to 180/180/180)
- 03 Superior acoustic performance (Rw 50-65)
- 04 Rapid construction with minimal site work
- 05 Factory quality control and precision
Top limitations
- 01 High initial capital cost ($230-$390 per m²)
- 02 Requires crane access for installation
- 03 Transport limitations for remote sites
- 04 Limited modification flexibility post-installation
- 05 Potential for thermal bridging if poorly detailed
Technical
Physical ·9
- Density
- 2100 kg/m³ Concrete wythe density (insulation core 15-35 kg/m³)
- Specific gravity
- 2.1 Concrete component only
- Porosity
- 12 % Concrete porosity, insulation excluded
- Water absorption
- 4.5 % 24-hour immersion test for concrete
- Hardness
- 5 Mohs Concrete surface hardness
- UV resistance
- Excellent
- Chemical resistance
- Good
- pH tolerance
- 3 – 11
- Surface roughness
- 3.2 μm Off-form finish Ra value
Mechanical ·7
- Tensile strength
- 3.2 MPa Concrete splitting tensile strength
- Compressive strength
- 32 MPa Typical concrete strength at 28 days
- Flexural strength
- 4.5 MPa Modulus of rupture
- Shear strength
- 0.65 MPa Concrete shear strength
- Poisson's ratio
- 0.2 Concrete Poisson's ratio
- Impact resistance
- High
- Creep resistance
- Good
Sustainability & Health
Embodied carbon & energy ·7
- Embodied carbon
- 145 kg CO₂e/m² 250mm panel including insulation
- Carbon footprint
- 320 kg CO₂e/m³ Concrete component, varies with cement content
- Embodied energy
- 2.8 GJ/m² Cradle to gate energy
- Water footprint
- 180 L/m² Manufacturing water use
- Recycled content
- 25 % Typical fly ash/slag content
- Renewable content
- 0 %
- Circular score
- 7 /10 High durability and recyclability
Compliance & Fire
Fire performance ·6
- Combustibility class
- Non-combustible
- Fire resistance level
- 180 minutes FRL 180/180/180 for 300mm panel
- Ignition temp
- 1200 °C Concrete degradation temperature
- Flame spread index
- 0 Non-combustible concrete surfaces
- Smoke dev. index
- 0 Non-combustible
- Heat release rate
- 0 kW/m² Non-combustible surfaces
Cost & Lifecycle
Capex & lead time ·6
- Material cost (range)
- 230 – 390 AUD/m² 2025 prices including installation
- Material cost (per unit)
- 290 AUD/m² Average installed cost
- Lead time
- 4 – 8 weeks Custom panel manufacture
- Lifecycle cost
- 420 AUD/m² 50-year NPV including energy savings
- Annual maintenance
- 2 AUD/m²/year Minimal maintenance required
- Market availability
- Good
Service life & durability ·3
- Expected lifespan
- 100 years With minimal maintenance
- Maintenance interval
- 10 years Sealant inspection/replacement
- Warranty period
- 10 years Typical structural warranty
Layer D
Where it's used
External load-bearing walls for residential and commercial buildings
High-rise apartment facades requiring thermal and acoustic performance
Cold storage facilities and controlled environment buildings
Bushfire-prone area construction (BAL-12.5 to BAL-FZ rated)
Warehouse and industrial building envelopes
Educational and healthcare facility walls
Tilt-up construction for rapid deployment
Cyclone-resistant construction in Northern Australia